Corvette 1997-2005

Alternator

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Diagnosis & Testing



Load Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the engine running, turn on the blower motor and the high beams (or other electrical accessories to place a load on the charging system).
  4.  
  5. Increase and hold engine speed to 2000 rpm.
  6.  
  7. Measure the voltage reading at the battery.
  8.  
  9. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  10.  

No Load Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  4.  
  5. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  6.  
  7. Start the engine and increase engine speed to approximately 1500 rpm.
  8.  
  9. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  10.  
  11. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  12.  
  13. If the voltage is within specifications, proceed to the next test.
  14.  

Voltage Test
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  4.  
  5. Using a DVOM set to volts DC, probe across the battery terminals.
  6.  
  7. Measure the battery voltage.
  8.  
  9. Write down the voltage reading and proceed to the next test.
  10.  

Removal & Installation



  1. Remove the accessory drive belt.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the generator electrical connector (1).
  6.  
  7. Remove the engine harness terminal from the generator by sliding the boot back along the cable, removing the engine harness cable nut (3), and the engine harness terminal from the stud.
  8.  
  9. Remove the generator bolts and generator.
  10.  

To install:

  1. Install the generator.
  2.  
  3. Install the generator bolts. Tighten the generator bolts to 50 Nm (37 ft. lbs.).
  4.  
  5. Install the engine harness terminal to the generator:
  6.  
  7. Install the engine harness terminal to the stud.
  8.  
  9. Install the engine harness cable nut (3). Tighten the engine harness cable nut to 13 Nm (10 ft. lbs.).
  10.  
  11. Slide the boot over the generator stud.
  12.  
  13. Connect the generator electrical connector.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Regulator connector and battery-to-alternator terminal from the rear of the alternator
     
    Accessory drive belt
     
    Alternator mounting bolts
     
    Alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator-5.7L engine, 6.0L engine similar

     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator mounting bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Regulator connector and battery-to-alternator terminals and torque the alternator terminal nut to 10 inch lbs. (13 Nm)
     
    Drive belt
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Regulator connector and battery-to-alternator terminal from the rear of the alternator
     
    Accessory drive belt
     
    Alternator mounting bolts
     
    Alternator

    Click image to see an enlarged view

    Fig. Remove alternator as shown

     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator mounting bolts and torque them to 37 ft. lbs. (50 Nm)
     
    Regulator connector and battery-to-alternator terminals and torque the alternator terminal nut to 10 inch lbs. (13 Nm)
     
    Drive belt
     
    Negative battery cable
     

  2.  

 
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